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Abstract:

A numerically controlled machining center for performing work on a
workpiece including a plurality of magazines holding a plurality of
tools, each magazine positioned a first distance from an adjacent
magazine, a plurality of spindles equal to the number of magazines and
movable relative to one another independent of the positions of the
magazines, the spindles movable apart from one another in a tool loading
position to accommodate large magazine sizes and movable toward one
another in a working position to allow the tools to work close together
to minimize waste, and a table for supporting a workpiece.

Claims:

1. A numerically controlled machining center for performing work on a
workpiece, comprising: (a) a plurality of magazines each holding a
plurality of tools for performing work on the workpiece, each magazine
being positioned at a first distance from an adjacent magazine, the first
distance being determined by one or more of magazine size, tool types and
number of tools in each magazine; (b) a plurality of spindles, equal in
number to the plurality of magazines and mounted for movement relative to
one another independent of the positions of the magazines, the plurality
of spindles operable for loading a tool from the plurality of magazines
while the plurality of spindles are spaced from one another, wherein each
spindle is moveable to a second distance apart from an adjacent spindle
when work is performed on the workpiece, the second distance being less
than the first distance for permitting the spindles to work relatively
close together to minimize waste; and (c) a support for holding the
workpiece.

2. The machining center of claim 1, wherein the plurality of spindles are
movable between a loading position for loading a tool, a working position
for performing work on the workpiece, and an intermediate position
between the loading position and the working position.

3. The machining center of claim 2, wherein the plurality of spindles are
farthest apart in the loading position and closest together in the
working position.

4. The machining center of claim 2, wherein the first distance is
measured between centers of adjacent magazines and the second distance is
measured between centers of adjacent spindles, and wherein the second
distance is less than the first distance when the plurality of spindles
are positioned in the working position.

5. The machining center of claim 1, wherein each magazine is rotatable to
position a preselected tool for loading a respective spindle.

6. The machining center of claim 1, wherein each of the spindles are
movable along one or more of the x, y and z axes.

7. The machining center of claim 1, wherein the support for holding the
workpiece is movable along one or more of the x, y and z axes.

8. The machining center of claim 1, wherein the support for holding the
workpiece is a table.

9. The machining center of claim 1, wherein the plurality of magazines
and the plurality of spindles are arranged in a plane or in a plurality
of parallel planes.

10. A numerically controlled machining center for performing work on a
workpiece, comprising: (a) a plurality of magazines holding a plurality
of tools, each magazine positioned a first distance from an adjacent
magazine; (b) a plurality of spindles equal in number to the number of
magazines and movable relative to one another independent of the
positions of the magazines, the spindles movable configured to move apart
from one another in a tool loading position and movable toward one
another in a working position to allow the tools to be spaced apart
during tool loading to accommodate for a large magazine size and work
close together to minimize waste; and (c) a table for supporting a
workpiece.

11. The machining center of claim 10, wherein the distance between
adjacent magazines is greater than the distance between adjacent spindles
when the adjacent spindles are positioned in the working position.

12. The machining center of claim 10, wherein the distance between
adjacent spindles is greater in the tool loading position than in the
working position.

13. The machining center of claim 10, wherein one or more of the
plurality of spindles and the table are movable along one or more of the
x, y and z axes.

14. A method for controlling the loading and movement of spindles in a
machining center, comprising the steps of: providing a machining center
including a plurality of magazines each holding a plurality of tools, a
plurality of spindles equal in number to the plurality of magazines and
movable relative to the magazines and one another independent of the
positions of the magazines, and a table for supporting a workpiece;
providing a CNC controller and a PLC controller for controlling rotation
of the plurality of magazines, tool loading and movement of the plurality
of spindles relative to the magazines and to one another; transferring
tools from the plurality of magazines to the plurality of spindles in a
loading position of the machining center; and moving the plurality of
spindles apart from one another as the plurality of spindles move between
the loading position and a working position for performing work on the
workpiece.

15. The method of claim 14, wherein each magazine is positioned at a
first distance from an adjacent magazine and each spindle is positioned
at a second distance part from an adjacent spindle when the spindles are
positioned in the working position, wherein the first distance is greater
than the second distance.

16. The method of claim 15, wherein the first distance is determined by
one or more of magazine size, tool types and number of tools in each
magazine.

17. The method of claim 14, further comprising an intermediate position
between the loading position and the working position.

18. The method of claim 14, wherein the table is movable along one or
more of the x, y and z axes and movement of the table is controlled by
one or more of the CNC controller and the PLC controller.

19. The method of claim 14, wherein the plurality of spindles are movable
along one or more of the x, y and z axes and movement of the plurality of
spindles is controlled by one or more of the CNC controller and the PLC
controller.

20. The method of claim 14, wherein each of the plurality of spindles is
independently loadable and controllable.

Description:

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims priority to U.S. Provisional Application
No. 61/656,621 filed Jun. 7, 2012, the entirety of which is incorporated
by reference herein.

TECHNICAL FIELD AND BACKGROUND OF THE INVENTION

[0002] The present invention relates generally to the field of machine
tools, and more particularly, to the field of automated machining centers
utilizing multiple tools that simultaneously operate on one or more
workpieces.

[0003] Machine tools have been in use for centuries. Rotary filing
machines date at least to the eighteenth century with milling machines
appearing a short time thereafter. Automation began in the early
twentieth century, and by the late twentieth century computers were
commonly utilized to control automation. Presently, it is common for a
numerically controlled automated machine tool to operate with multiple
tools functioning at the same time on one or more workpieces.

[0004] For instance, in a manufacturing process where milling of a
workpiece is necessary, the workpiece is typically held on a table and
the machine utilizes one, two, three, four, or more spindles each
securing a tool. The spindles may be connected to one another and move
together in parallel motion. The table may move in the x-y plane and the
spindles of the machine along the z axis. The table may also move in the
x-y plane as well as along another axis or multiple other axes and/or the
spindles may also move in the x-y plane. Thus, it is possible to machine
a 2-D or 3-D workpiece along multiple axes.

[0005] As refinement of the computer driven automation of machine tools
has advanced, so has the ability to adapt machines for multiple tools.
Rather than having multiple machines wherein the spindles of a particular
machine each hold only one tool, spindles may be made adaptable to
multiple tools. For some time, tools in a spindle were required to be
manually changed, for instance, if a tool became damaged or required
sharpening/adjustment or if a different tool was desired. With advances
in computerized automation, a machine may contain a magazine of tools
wherein the spindle is adapted to cooperate with the magazine and
automatically change tools as programmed. Magazines are typically located
near the spindle, contain multiple tools, and are rotatable such that as
it rotates a tool can be removed from the spindle and a different tool
placed in the spindle. Spindles may be moved between use and loading
positions.

[0006] Because a spindle may be adaptable to many different sizes and
types of tools, the size of the magazines can vary. When magazines are
large in order to contain a large number of tools, they gain flexibility
in being able to perform many different functions with individual
spindles acting in a single machine tool. A magazine may be supplied with
tools allowing the spindle to drill, cut, grind, mill, punch, etch, etc.,
by rotating the magazine to a different position. However, by adding
tools to a magazine and thereby increasing magazine size, efficiency of
the operation on the workpiece may suffer because large magazines require
spindles to be separated by a greater distance. In other words, spacing
between spindles is directly impacted by magazine size. Spacing can
become an important factor with respect to waste material from a
workpiece. For example, four spindles may operate on a flat workpiece,
with each spindle cutting a portion of the workpiece. Because of the
minimum spacing required between spindles, voids are present between
spindles in which the workpiece cannot be worked on, resulting in waste
product.

[0007] Thus, there exists a need for a machining center that permits a
wide range of tools to be utilized by each spindle while permitting
multiple spindles to function at a relatively close distance to one
another, thereby reducing waste.

BRIEF SUMMARY OF THE INVENTION

[0008] It one aspect, the presented invention is directed to a numerically
controlled machining center configured to reduce the waste associated
with performing work on a workpiece.

[0009] In another aspect, the machining center includes a plurality of
machine tool spindles (hereinafter "spindles"), wherein each spindle is
movable and configured to access at least one magazine of a plurality of
magazines holding a plurality of tools for working the workpiece.

[0010] In a further aspect, the center of each of the magazines is located
at a first distance apart from the center of an adjacent magazine or
magazines

[0011] In a further aspect, each spindle is configured to load a selected
tool from a magazine and then detach and move toward (i.e. closer) to an
adjacent spindle such that once positioned, the center of each spindle is
a second distance apart from the center of an adjacent spindle, wherein
the second distance is less than the first distance.

[0012] In a further aspect, loaded, adjacent spindles are closer together
than their respective magazines are to adjacent magazines.

[0013] In a further aspect, the machining center is configured to operate
in a tool loading position where the magazines rotate and tools are
changed, a working position where tools do work to a workpiece, and an
intermediate position where the spindles move through a series of
positions from the loading position to the working position or from the
working position to the loading position.

[0014] In a further aspect, in the intermediate position the spindles move
in the direction toward one another (i.e., closer together) before
starting work on the workpiece, or move away from one another (i.e.,
further apart) after performing work on the workpiece.

[0015] In a further aspect, a machining center is provided herein wherein
magazines and spindles are respectively arranged in a plane or in a
plurality of parallel planes.

[0016] In a further aspect, a machining center is provided herein wherein
the second distance can be programmed to vary from one spindle to another
adjacent spindle.

[0017] In a further aspect, the workpiece is held by a table positioned
beneath the spindles that may be numerically programmed to automatically
move along one or more of the x and y axes.

[0018] In a further aspect, the table moves along a plurality of axes
and/or at various angles with respect to the spindles.

[0019] In a further aspect, each of the plurality of spindles may move
along one or more of the x, y and z axes.

[0020] In a further aspect each of the plurality of spindles may move
along a plurality of axes and/or at various angles with respect to the
table.

[0021] In a further aspect, the plurality of spindles are surrounded by a
debris vacuum system for removing bits of debris collected as a byproduct
of the machining process during the working position.

[0022] To achieve the foregoing and other aspects and advantages, in one
embodiment provided herein is a numerically controlled machining center
for performing work on a workpiece including a plurality of magazines
wherein each magazine holds a plurality of tools for performing work on
the workpiece, wherein each magazine is positioned at a first distance
from an adjacent magazine determined by the size, number and types of
tools held in each magazine, a plurality of spindles, equal in number to
the plurality of magazines and mounted for movement relative to one
another independent of the positions of the magazines, the plurality of
spindles operable for grasping and securing a tool from the magazines
while the spindles are spaced from one another, wherein each spindle is
moveable to a second distance apart from an adjacent spindle when work is
performed on the workpiece, the second distance being less than the first
distance for permitting the spindles to work relatively close together to
minimize waste, and a support for holding the workpiece.

[0023] In a further embodiment, the plurality of spindles are movable
between a loading position for loading a tool, a working position for
performing work on the workpiece, and an intermediate position between
the loading position and the working position, wherein the plurality of
spindles are farthest apart in the loading position and closest together
in the working position.

[0024] In a further embodiment, the first distance is measured between
centers of adjacent magazines and the second distance is measured between
centers of adjacent spindles, and wherein the second distance is less
than the first distance when the plurality of spindles are positioned in
the working position.

[0025] In a further embodiment, the machining center includes a CNC
controller and a PLC controller for controlling rotation of the plurality
of magazines, tool loading and movement of the plurality of spindles
relative to the magazines and to one another, among other functions.

[0026] In another embodiment, provided herein is a numerically controlled
machining center for performing work on a workpiece including a plurality
of magazines holding a plurality of tools, each magazine positioned a
first distance from an adjacent magazine, a plurality of spindles equal
in number to the number of magazines and movable relative to one another
independent of the positions of the magazines, the spindles movable
configured to move apart from one another in a tool loading position and
movable toward one another in a working position to allow the tools to be
spaced apart during tool loading to accommodate for a large magazine size
and work close together to minimize waste, and a table for supporting a
workpiece.

[0027] In a further embodiment, the distance between adjacent magazines is
greater than the distance between adjacent spindles when the adjacent
spindles are positioned in the working position, and the distance between
adjacent spindles is greater in the tool loading position than in the
working position.

[0028] In yet another embodiment, provided herein is a method for
controlling the loading and movement of spindles in a machining center
including the steps of providing a machining center including a plurality
of magazines each holding a plurality of tools, a plurality of spindles
equal in number to the plurality of magazines and movable relative to the
magazines and one another independent of the positions of the magazines,
and a table for supporting a workpiece, providing a CNC controller and a
PLC controller for controlling rotation of the plurality of magazines,
tool loading and movement of the plurality of spindles relative to the
magazines and to one another, transferring tools from the plurality of
magazines to the plurality of spindles in a loading position of the
machining center, and moving the plurality of spindles apart from one
another as the plurality of spindles move between the loading position
and a working position for performing work on the workpiece.

[0029] Additional features, aspects and advantages of the invention will
be set forth in the detailed description which follows, and in part will
be readily apparent to those skilled in the art from that description or
recognized by practicing the invention as described herein. It is to be
understood that both the foregoing general description and the following
detailed description present various embodiments of the invention, and
are intended to provide an overview or framework for understanding the
nature and character of the invention as it is claimed. The accompanying
drawings are included to provide a further understanding of the
invention, and are incorporated in and constitute a part of this
specification.

BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Features, aspects and advantages of the present invention are
better understood when the following detailed description is read with
reference to the accompanying drawings, in which:

[0031]FIG. 1 is a perspective view of a machining center according to one
embodiment of the invention and including four spindles, four magazines,
a table and two workpieces;

[0032]FIG. 1A is a perspective view of a machining center according to
another embodiment of the invention and including six spindles, six
magazines, a table and two workpieces;

[0034]FIG. 3 is a front elevation view of the machining center of FIG. 1;

[0035]FIG. 4 is a side elevation view of the machining center of FIG. 1;

[0036]FIG. 5 is a front perspective view of a machining center
illustrating the spindle loading position;

[0037]FIG. 6 is a front perspective view of a machining center
illustrating an intermediate position wherein a tool has been loaded and
spindles moving closer together and towards the workpiece;

[0038]FIG. 7 is a front perspective view of a machining center
illustrating first distance (D1) between magazine centers and second
distance (D2) between spindle centers in the intermediate position;

[0039] FIG. 8 is a front perspective view of a machining center
illustrating a working position and x- and y-axis movement;

[0040]FIG. 9 is a front perspective view of a machining center
illustrating an intermediate position wherein the plurality of spindles
move apart and in a direction away from the workpiece; and

[0041]FIG. 10 is a front perspective view of a machining center
illustrating an intermediate position wherein tools have completed work
on the workpiece and are returning to the loading position.

DETAILED DESCRIPTION OF THE INVENTION

[0042] The present invention will now be described more fully hereinafter
with reference to the accompanying drawings in which exemplary
embodiments of the invention are shown. However, the invention may be
embodied in many different forms and should not be construed as limited
to the representative embodiments set forth herein. The exemplary
embodiments are provided so that this disclosure will be both thorough
and complete, and will fully convey the scope of the invention and enable
one of ordinary skill in the art to make, use and practice the invention.
Like reference numbers refer to like elements throughout the various
drawings.

[0043] Referring now to the drawings, FIGS. 1-4 illustrate a machining
center 10 generally including a plurality of spindles 11, a plurality of
magazines 20, a plurality of tools 31 in each magazine 20, a table 40, a
set of table rails 41, a set of spindle rails 12, a plurality of
workpieces 50, a debris collection hood 60, and a debris collection
conduit 61. Each spindle 11 is loaded with a preselected tool 32 from the
plurality of tools 31. The machining center 10 is shown FIGS. 1-4 in a
tool loading position with the spindles 11 acting in cooperation with the
magazines 20. Tools 31 are loaded into a magazine 20 and are ready to be
transferred from the magazine 20 to the spindles 11.

[0044] One or more workpieces 50 are loaded onto the table 40. Table 40
has table rails 41 that allow the table to move along the y axis. The
machining center 10 may additionally be configured to move the table
along one or more the x, y and z axes. The plurality of spindles 11 move
along a set of spindle rails 12 along the x axis. The machining center 10
may also be configured to move the spindles along one or more of the x, y
and z axes, as shown in FIG. 6. FIGS. 1-4 also show debris conduits 61
that carry debris collected from debris collection hoods 60 as the
spindles 11 and tool 32 perform work on the workpieces 50. FIG. 1A shows
an alternative embodiment of a machining center including additional
spindles 11.

[0045] The spindles 11 of the machining center 10 are configured to be
numerically programmed to move closer to each other after disengaging
from the magazines 20. FIGS. 5-10 show various stages of movement of the
spindles between a tool loading position (see FIGS. 5 and 6) and a
working position (see FIGS. 7 and 8), through a series of intermediate
positions (see FIG. 9). In other words, the spindles 11 are positioned
farthest apart in the tool loading position to accommodate for large
magazine size and spacing, and closest together in the working position
to permit the tools to operate close together to minimize waste. In the
intermediate positions the tools may be moving apart and/or in the
direction of one of the magazines and the workpiece.

[0046]FIG. 5 shows the machining center 10 where the spindles 11 have
begun to disengage from the magazines 20. Tools 31 remain in the
magazines 20 and tools 32 have been loaded into the spindles 11. The
magazines 20 are, and remain throughout the movement, a first distance D1
apart from one another. Distance D1 may be determined by one or more of
magazine size, tool size, types of tools in the magazines, number of
tools in the magazines, etc.

[0047]FIG. 6 shows the machining center 10 where the spindles 11 have
begun to move downward and towards the right as part of the intermediate
position. The distance D1 between the magazines 20 remains the same.

[0048]FIG. 7 shows the machining center 10 where the spindles 11 have
moved further downward and to the right such that the distance D2 between
the spindles is smaller (i.e., less) than the distance D1 between the
magazines 20. The tools 32 in the spindles 11 are nearly in contact with
the workpiece 50 resting on the table 40. Also, the debris collection
hood 60 surrounds the tool 32 so as to prepare to collect debris produced
from the machining process. This debris will be collected through the
debris collection hood 60 and be passed and channeled through the debris
collection conduits 61.

[0049] FIG. 8 shows the machining center 10 in the working position where
tools 32 are loaded in the spindles 11 and are performing work on the
workpiece 50. The debris collection hoods 60 are vacuuming debris and
passing the debris through the debris collection conduit 61. The
magazines 20 remain the same distance D1 apart and the spindles are a
smaller distance D2 apart from one another. The table 40 moves the
workpiece 50 along a y axis. The spindles 11 move together along the
spindle rails 12 along an x axis. The magazines 20 remain loaded with
additional tools 31.

[0050]FIG. 9 shows the machining center 10 in the intermediate position,
returning from the working position shown in FIG. 8 to the loading
position of FIG. 5. The tool 32 that has completed working on the
workpiece 50 is still loaded in the spindle 11. The debris collection
hood 60 is moving upward with the spindle 11. Tools 31 remain in the
magazine 20 and are ready to be loaded into the spindles 11 once the
spindles 11 reach the loading position and unload existing tools 32 back
into the magazines 20.

[0051]FIG. 10 shows the machining center 10 in the intermediate position,
returning from the working position shown in FIG. 8 to the loading
position shown in FIG. 5. The spindles 11 are moving upward and to the
left. The tool 32 that has completed working on the workpiece 50 is still
loaded in the spindle 11. The debris collection hood 60 is moving upward
and leftward with the spindle 11. Tools 31 remain in the magazines 20 and
are ready to be loaded into the spindles 11 once the spindles 11 reach
the loading position and unload existing tools 32 back into the magazines
20.

[0052] Each magazine 20 and spindle 11 may be provided with a respective
computer numeric controlled (CNC) controller and respective programmable
logic controller (PLC), which may also be single controllers with
different channels. The controllers receive signals (information)
relating to the current status and positional information of the spindles
and magazines. On the basis of this information, the PLC controller
controls the removal of a tool from, and the return of a tool to, its
respective magazine and the loading and unloading of the spindles. CNC
and PLC controllers are well known in the field of machine control.

[0053] The foregoing description provides embodiments of the invention by
way of example only. It is envisioned that other embodiments may perform
similar functions and/or achieve similar results. Any and all such
equivalent embodiments and examples are within the spirit and scope of
the present invention and are intended to be covered by the appended
claims.